Weird Fuel Pump leak from top of housing?

[beewstew]

Chasing down a fuel leak, 2004 xc70. Fuel was dripping from the filter location. Replaced filter, leak persisted.

Thinking the pump to tank hose was the problem, I tore apart the back seat to get access to the fuel pump. Much thanks to the old thread from @Allgonquin !!!! viewtopic.php?f=9&t=67480

With both fuel pump covers removed, the passenger side tank access was wet, driver side was dry enough for a mouse's nest.

With engine running, the + shaped divot slowly filled with fuel - this is the source of the leak.

Looking for confirmation - this means I should get an entirely new fuel pump assembly? A cracked housing seems like a really weird way for the fuel system to leak - there's no exposure to external damage at all!

Back seat removed, both access holes visible.

Driver's side access is dry, clean, aside from mouse nest.

passenger side pump access, before starting. No visible fuel, but note clean plastic.

Car running, + reservoir slowing filling with fuel.

Close up of + reservoir slowly(??? this was after 1 minute) filling with fuel.

Update: after an hour of driving the epoxy seems ok, but there's a slight odor of gas. Going to run through a tank of gas (down to E) before sending accepting that this fix is ok and sending the replacement fuel pump back to the nice people at FCP.

Related, I asked Volvo Cars about "Recall 220", which is for this specific failure mode. They told me to go to the dealer (150 miles away)...

Cured epoxy plug on the top of the fuel tank after an hour of driving.

[jonesg]

the plastic fuel tank causes it, easy fix, get some JB weld, chemical and gas proof version.
Spray the pump top + area with brake fluid, clean with paper towel and spray again until spotless.
Let it dry and mix up the JB weld, spoon the whole lot in there, it sets in 4 hrs but give it 24 hrs to fully cure.
Don't sand the surface, don't buy the quick set version, slow cure is best.
I did mine 8 years ago, never leaked a drop since.
https://www.amazon.com/Professional-Ste ... 220&sr=8-5

[beewstew]

@jonesg thanks for the suggestion. Brake disc cleaner to clean? Also, just the + area with jb weld or some other place too?

[volvolugnut]

This is typical failure. If you plan to keep this vehicle a long time, consider replacing the entire fuel pump while you have it open. Then you have no fuel pump worries for a long, long time.
volvolugnut

[beewstew]

This is the $10 fix for now. Won't know that it works until tomorrow...

JB weld in area that I saw the fuel leaking from.

[scot850]

Not an un-common issue as the others have mentioned. A friend just did the same repair on his son's 01 S60 T5. The top of the pumps crack and leak. Good catch though!

Neil.

[jonesg]

This is the $10 fix for now. Won't know that it works until tomorrow...

PXL_20250323_171042567.jpg

thats the ticket.
Don't turn the ignition on to check for leaks or it will set an SRS code.
Make sure all the seatbelt sensors are connected before ignition on.

[Vova585]

I would not mess with fuel system. Better get yourself new pump assembly with new rubber ring and sleep well. If budget is not permitting such repair at this time-buy used unit and install new rubber seal. It is your life and safety lf other next to you.

[Krons]

This is the $10 fix for now. Won't know that it works until tomorrow...

PXL_20250323_171042567.jpg

Volvo did have a recall on those, oddly only in southern US states, cause-you know, cars never change locations lol. My 2002 with 180,000 miles at the time got a free replacement a few years ago. I would call Volvo customer care and kindly ask due to the safety nature of they would cover a replacement under that recall. I had epoxied mine to get it to the dealership.

Some links:
https://volvo.custhelp.com/app/answers/ ... recall-220

https://static.nhtsa.gov/odi/rcl/2009/R ... 3-8017.pdf

viewtopic.php?t=91717

[DavidE7]

The new pump flanges following the recall are made with a stronger POM plastic. The old parts are a standard natural/white color POM. The new parts use a dull yellow plastic that is BASF Ultraform POM C13031 XF for hot fuel application. I used this same POM for diesel fuel tank vapor vent valves. BASF was really pushing the new material in the auto industry for fuel system parts in 2005/2006 and I had no idea why until my fuel flange leaked and the replacement part had the telltale dull yellow color.